Electromagnetic support tooling for composite part curing

ABSTRACT

Methods and apparatuses for electromagnetic support tooling for use in composite part curing are described. In one example, a support tooling, such as a mandrel, includes an elastomeric housing that has ferromagnetic components. The mandrel also has electro-magnetic coils positioned within the elastomeric housing and operable to generate magnetic fields to repel or attract the ferromagnetic components of the elastomeric housing to the electro-magnetic coils. When the ferromagnetic components of the elastomeric housing are repelled by the electro-magnetic coils, the elastomeric housing has a rigid surface state. When the ferromagnetic components of the elastomeric housing are attracted to the electro-magnetic coils, the elastomeric housing is collapsed.

CROSS REFERENCE TO RELATED APPLICATION

The present disclosure claims priority to and is a divisional of U.S.application Ser. No. 15/005,156 filed on Jan. 25, 2016, the entirecontents of which are herein incorporated by reference.

FIELD

The present disclosure generally relates to methods and equipment forfabricating composite resin parts, and more particularly to anelectromagnetic mandrel system used in curing composite parts.

BACKGROUND

Composite parts, such as those used in the manufacture of aircraft, canbe constructed using various production methods, such as filamentwinding, tape placement, overbraid, chop fiber roving, coating, handlay-up, or other composite processing techniques and curing processes.Most of these processes use a rigid cure tool/mandrel on which compositematerial is applied and then cured into a rigid composite part. Forexample, automated fiber placement (AFP) machines may be used to placefiber reinforcements on molds or mandrels to form composite layups.Following, composite parts may be cured within an autoclave that appliesheat and pressure to the part during a cure cycle.

Some composite part geometries include internal cavities that mayrequire a tool such as a supporting bladder that is placed in the cavityto ensure that the part geometry is properly maintained duringapplication of composite material or when processed under autoclavepressure. The supporting bladder may be an inflatable bladder that caneasily fit into an internal cavity prior to cure and then be inflatedduring an autoclave cure process so as to react to the autoclavepressure force applied to the part. Typically, such inflatable bladdersare pressurized by venting them to the autoclave pressure through avacuum bag.

However, the bladders that are used to support a composite part (e.g., astringer or other longitudinal structural piece in a framework) forautoclave curing may not suitable when alternatively curing the partout-of-autoclave (e.g., as performed with repairs). In this case, thepart and the bladder are exposed to different temperature and pressureconditions than in an autoclave such that an inflatable bladder may notperform properly and could in fact negatively impact final partcharacteristics. This creates a need for a support tool that can fitinto a composite part cavity prior to cure, can conform to the internalgeometry of the part cavity during out-of-autoclave curing, and finallycan reduce in size to be removed from the part after cure.

SUMMARY

In one example, a mandrel is described that comprises an elastomerichousing having ferromagnetic components, and one or moreelectro-magnetic coils positioned within the elastomeric housing andoperable to generate one or more magnetic fields to repel or attract theferromagnetic components of the elastomeric housing to the one or moreelectro-magnetic coils. When the ferromagnetic components of theelastomeric housing are repelled by the one or more electro-magneticcoils, the elastomeric housing has a rigid surface state. When theferromagnetic components of the elastomeric housing are attracted to theone or more electro-magnetic coils, the elastomeric housing iscollapsed.

In another example, another mandrel is described that comprises anelastomeric housing having a polarized magnetic material, and one ormore electro-magnetic coils positioned within the elastomeric housingand operable to generate one or more magnetic fields to repel or attractthe ferromagnetic components of the elastomeric housing to the one ormore electro-magnetic coils. When the ferromagnetic components of theelastomeric housing are repelled by the one or more electro-magneticcoils, the elastomeric housing has a first volume. When theferromagnetic components of the elastomeric housing are attracted to theone or more electro-magnetic coils, the elastomeric housing has a secondvolume that is smaller than the first volume.

In yet another example, a method is described comprising providing anelastomeric housing having ferromagnetic components, and operating oneor more electro-magnetic coils in the elastomeric housing to generateone or more magnetic fields to repel or attract the ferromagneticcomponents of the elastomeric housing to the one or moreelectro-magnetic coils. When the ferromagnetic components of theelastomeric housing are repelled by the one or more electro-magneticcoils, the elastomeric housing has a rigid surface state. When theferromagnetic components of the elastomeric housing are attracted to theone or more electro-magnetic coils, the elastomeric housing iscollapsed.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE FIGURES

The novel features believed characteristic of the illustrativeembodiments are set forth in the appended claims. The illustrativeembodiments, however, as well as a preferred mode of use, furtherobjectives and descriptions thereof, will best be understood byreference to the following detailed description of an illustrativeembodiment of the present disclosure when read in conjunction with theaccompanying drawings, wherein:

FIG. 1 illustrates an example system including a mandrel be used to formand/or cure a part layup, according to an example embodiment.

FIG. 2 illustrates an example of a composite component that may benefitfrom use of the mandrel as described in FIG. 1, according to an exampleembodiment.

FIG. 3 illustrates an example configuration of the elastomeric housingin which the ferromagnetic components are embedded within at least oneof a plurality of walls of the elastomeric housing, according to anexample embodiment.

FIG. 4 illustrates another example configuration of the elastomerichousing in which the ferromagnetic components are embedded within a wallof the elastomeric housing, according to an example embodiment.

FIG. 5 illustrates another example configuration of the elastomerichousing in which the ferromagnetic components are positioned on aninterior surface of the wall of the elastomeric housing, according to anexample embodiment.

FIG. 6 illustrates another example configuration of the elastomerichousing in which the ferromagnetic components are positioned on theexterior surface of the wall of the elastomeric housing, according to anexample embodiment.

FIG. 7 illustrates another example configuration of the elastomerichousing in which the ferromagnetic components comprise a coating on theinterior surface of the wall, according to an example embodiment.

FIG. 8 illustrates another example configuration of the elastomerichousing in which the ferromagnetic components comprise the coating onthe exterior surface of the wall, according to an example embodiment.

FIG. 9 illustrates an example configuration of the elastomeric housingin which some of the ferromagnetic components are positioned laterallyalong the elastomeric housing so as to be linearly perpendicular to acenterline of the elastomeric housing, according to an exampleembodiment.

FIG. 10 illustrates an example configuration of the elastomeric housingin which some of the ferromagnetic components are positionedlongitudinally along the elastomeric housing so as to be linearlyparallel to the centerline of the elastomeric housing, according to anexample embodiment.

FIG. 11 illustrates an example configuration of the elastomeric housingwith the electro-magnetic coil positioned in the elastomeric housing,according to an example embodiment.

FIG. 12 illustrates an example configuration of the elastomeric housingwith the electro-magnetic coil positioned in the elastomeric housing andoperated to collapse the elastomeric housing, according to an exampleembodiment.

FIG. 13 illustrates an example of the mandrel including a plurality oftool segments connected to each other within the elastomeric housing,according to an example embodiment.

FIG. 14 illustrates an example of the multiple connected plates,according to an example embodiment.

FIG. 15 shows a flowchart of an example method for operating themandrel, according to an example embodiment.

FIG. 16 shows a flowchart of another example method for operating themandrel, according to an example embodiment.

DETAILED DESCRIPTION

Disclosed embodiments will now be described more fully hereinafter withreference to the accompanying drawings, in which some, but not all ofthe disclosed embodiments are shown. Indeed, several differentembodiments may be described and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments aredescribed so that this disclosure will be thorough and complete and willfully convey the scope of the disclosure to those skilled in the art.

Within examples, mechanical support tooling and/or mandrel for compositepart curing is described. Additionally, controlled electromagneticinduced extraction of a cured composite part from the elastomerictooling mandrel is described. The mandrel may comprises an elastomerichousing that has ferromagnetic components, and an electro-magnetic coilpositioned within the elastomeric housing that is operable to generate amagnetic field to repel or attract the ferromagnetic components of theelastomeric housing to the electro-magnetic coil. When the ferromagneticcomponents of the elastomeric housing are repelled by theelectro-magnetic coil, the elastomeric housing has a rigid surface stateand when the ferromagnetic components of the elastomeric housing areattracted to the electro-magnetic coil, the elastomeric housing iscollapsed. Thus, by utilizing a magnetic field to attract or repel anouter elastomeric bladder from or to a center coil, the housing may berigid or collapsed.

As one example, an outer elastomeric bladder of the mandrel is moldedwith a homogeneous mixture of a ferrous powder or similar within theelastomer. The bladder is assembled over a solid mandrel tool.Incorporated within the mandrel may be one or a series ofelectro-magnetic coils configured such that when activated the outerelastomeric bladder is repelled or attracted to the hard tooling form.

The mandrel can be used to fill a cavity of the composite part thatneeds to be cured, and then can reduce in size (e.g., such as areduction in cross-sectional dimension) to be pulled out and removed.Geometry of the mandrel allows the mandrel to reduce in size to beinserted into an uncured composite part and then expanded to form asolid stiffener capable of withstanding out-of-autoclave cure pressure.The mandrel is further reusable since the mandrel can be reduced in sizeafter cure to be removed from the part.

Referring now to FIG. 1, a mandrel 100 may be used to form and/or cure apart layup 102 comprising multiple plies (not shown) of fiber reinforcedpolymer resin, according to an example embodiment. For example, multipleplies of fiber reinforced polymer plies are laid up over the mandrel 100in order to form the plies into a desired part shape. The part layup 102may partially or fully surround the mandrel 100, such that the mandrel100 is at least substantially enclosed by the part layup 102. Themandrel 100 includes an elastomeric housing 104 in which a tool segment106 is positioned, and the elastomeric housing 104 forms an enclosurethat may collapse inwardly when the elastomeric housing 104 is placedinto a flexible state to allow the mandrel 100 to be withdrawn from thepart layup 102 either after the layup is compacted and/or cured. Thetool segment 106 may be expanded and collapsed to allow for removal. Thetool segment 106 may further include joint linkage(s) 108 that allow forconnection to other tool segments. The elastomeric housing 104 of thetool segment 106 further includes ferromagnetic components 110 withinthe elastomeric housing 104. One or more electro-magnetic coils 109 arepositioned within the elastomeric housing 104 and are operable togenerate magnetic fields to repel or attract the ferromagneticcomponents 110 of the elastomeric housing 104 to the electro-magneticcoils 109. When the ferromagnetic components 110 of the elastomerichousing 104 are repelled by the electro-magnetic coils 109, theelastomeric housing 104 has a rigid surface state. When theferromagnetic components 110 of the elastomeric housing 104 areattracted to the electro-magnetic coils 109, the elastomeric housing 104is flexible or collapsed.

In another example, when the ferromagnetic components 110 of theelastomeric housing 104 are repelled by the electro-magnetic coils 109,the elastomeric housing 104 has a first volume. When the ferromagneticcomponents 110 of the elastomeric housing 104 are attracted to theelectro-magnetic coils 109, the elastomeric housing 104 has a secondvolume that is smaller than the first volume, and thus, can be removedfrom the composite part being cured.

A power source 111 may also be included within the tool segment 106 tooperate the electro-magnetic coils 109. In another example, the powersource 111 may be a component separate from the mandrel 100, and may bein wired communication to the electro-magnetic coils 109 to power theelectro-magnetic coils 109.

The mandrel 100 may be formed of any elastomeric material, such asTeflon® (E.I. du Pont de Nemours and Company) coated silicone or hardrubber, and may be pliable to enable the mandrel 100 to conform tovarious configurations. The elastomeric housing 104 may be formed, forexample and without limitation, from flexible silicon rubber, and thus,the elastomeric housing 104 may be a flexible housing or an elastomerhousing such that the housing may contact the uncured composite layupwithout damage to the layup and/or without contamination to the layup.

The ferromagnetic components 110 may be pieces of magnets composed ofany type of magnetic material and arranged within the elastomerichousing 104 in a predetermined manner. As one example, the elastomerichousing 104 may include a mixture of the ferromagnetic components 110and rubber such that the ferromagnetic components 110 are embeddedwithin the elastomeric housing 104. As another example, theferromagnetic components 110 may comprise a polarized magnetic material,or other type of permanent magnets including any kind of magneticmaterial such as neodymium-iron-boron or any of the rare Earth magnets.The ferromagnetic components 110 may be separate solid componentsincluded in walls of the elastomeric housing 104 (such as individualpieces of magnet material), or may be magnetic particles homogeneouslymixed within a surface of the elastomeric housing 104 in a predeterminedmanner. The ferromagnetic components 110 may further include smallermagnetic particles (e.g., small pieces of magnets) embedded in theelastomer housing 104. Any type of magnets may be used for theferromagnetic components 110. The ferromagnetic components 110 may alsobe structures that are disposed within, but are separate from theelastomeric housing 104.

The part layup 102 may be cured to form any of a variety of compositecomponents, structures, or parts that form full or partial enclosureshaving uniform or non-uniform cross sections along their lengths. Forexample, the cured part may comprise a duct (not shown) or a conduit(not shown) used to transport fluids, such as, for example and withoutlimitation, air ducts and fuel lines used in a wide variety ofapplications, including vehicles. An example of a composite componentthat may benefit from use of the mandrel 100 and the tool segment 106 toform the part layup 102 is illustrated in FIG. 2.

In FIG. 2, the disclosed flexible apparatus and curing method may beemployed to cure a variety of composite resin parts of variousgeometries, having one or more internal cavities. For example, andwithout limitation, the disclosed flexible bladder and curing method maybe used in fabrication of a fiber reinforced composite resin stringer200. In one arrangement, the stringer 200 may comprise a multi-ply layupof prepreg. In the illustrated arrangement, the stringer 200 comprises ahat section 202 forming an internal stringer cavity 204, a pair oflaterally extending flange sections 206, and a substantially flat skinsection 208 that is consolidated together with the flange sections 206during curing. As those of ordinary skill in the art will recognize,alternative stringer geometries are possible.

The stringer 200 may be fabricated using the mandrel 100 and the toolsegment 106 in FIG. 1 by applying the part layup 102 to the mandrel 100with the tool segment 106 inserted into the mandrel 100. After curing,the part layup 102 forms the stringer 200. The tool segment 106 fillsthe stringer cavity 204 that is a hollow trapezoidal space or opening.The tool segment 106 functions to so as to maintain a shape and contourof the stringer 200 during cure and is collapsible to be reduced in sizeand is removable after cure.

In other embodiments, the stringer 200 is preformed and is uncured. Themandrel 100 may have a cross-section that can reduce in size so that themandrel 100 can be positioned within the stringer cavity 204 and has ashape that substantially conforms to the corresponding stringer cavity204 when the mandrel 100 is expanded such that the mandrel 100 andelastomeric housing 104 may provide support to the stringer 200 duringcuring. The mandrel 100 of the illustrated embodiment has a trapezoidalshape to conform to a hat-shaped stringer 200, although the mandrelcould have any number of other shapes to conform to differently shapedstringers.

As used herein, by the term “substantially” it is meant that the recitedcharacteristic, parameter, or value need not be achieved exactly, butthat deviations or variations, including for example, tolerances,measurement error, measurement accuracy limitations and other factorsknown to skill in the art, may occur in amounts that do not preclude theeffect the characteristic was intended to provide. Similarly, the term“about” includes aspects of the recited characteristic, parameter, orvalue allowing for deviations or variations, including for example,tolerances, measurement error, measurement accuracy limitations andother factors known to skill in the art, and also ranges of theparameters extending a reasonable amount to provide for such variations.

Example composite material used for the stringer 200 may be generally alightweight material, such as an uncured pre-impregnated reinforcingtape or fabric (i.e., “prepreg”). The tape or fabric can include aplurality of fibers such as graphite fibers that are embedded within amatrix material, such as a polymer, e.g., an epoxy or phenolic. The tapeor fabric could be unidirectional or woven depending on a degree ofreinforcement desired. Thus, the prepreg tape or fabric is laid onto themandrel 100 (or mold) to pre-form the tape or fabric into a desiredshape of the stringer 200 as defined by the mandrel 100. The stringer200 could be any suitable dimension to provide various degrees ofreinforcement, and could comprise any number of plies of prepreg tape orfabric.

FIGS. 3-10 illustrate example configurations of the elastomeric housing104 that show various arrangements of the ferromagnetic components 110within or on the elastomeric housing 104, according to exampleembodiments. In FIGS. 3-10, the elastomeric housing 104 has asubstantially trapezoidal shape. This trapezoidal shape works well tofill the stringer cavity 204 of the stringer 200, shown in FIG. 2, forcuring. In other examples, the elastomeric housing 104 may be configuredin other shapes as needed to fill a specific cavity of a composite part.As an example, the elastomeric housing 104 may be rectangular or squareinstead of a triangular shape. In still other examples, the elastomerichousing 104 may form a rounded hat shape, or still other shapes arepossible depending on application of the mandrel 100.

FIG. 3 illustrates an example configuration of the elastomeric housing104 in which the ferromagnetic components 110 are embedded within atleast one of a plurality of walls of the elastomeric housing 104,according to an example embodiment. In FIG. 3, the elastomeric housing104 includes an outer wall 120, and inner walls 122 and 124. Theferromagnetic components 110 are embedded between the outer wall 120 andthe inner wall 122. The ferromagnetic components 110 are shown as stripsof pieces of material arranged in a predetermined manner within thewall. The inner walls 122 and 124 may define an optional secondaryinternal structure or bladder that is within the elastomeric housing104, for example. The ferromagnetic components 110 may be positionedoutside of this secondary internal structure.

FIG. 4 illustrates another example configuration of the elastomerichousing 104 in which the ferromagnetic components 110 are embeddedwithin a wall 126 of the elastomeric housing 104, according to anexample embodiment. The wall 126 may be defined by an exterior surface128 and an interior surface 130. In this example, the ferromagneticcomponents 110 are shown as circular pieces of material dispersed withinthe wall 126, however, the ferromagnetic components 110 may be any sizeor shape as desired for a specific application of the mandrel 100.

FIG. 5 illustrates another example configuration of the elastomerichousing 104 in which the ferromagnetic components 110 are positioned onan interior surface 128 of the wall 126 of the elastomeric housing 104,according to an example embodiment. The wall 126 has the interiorsurface 128 and an exterior surface 130, and in the configuration shownin FIG. 5, the ferromagnetic components 110 include strips of magneticmaterial positioned on the interior surface 128 of the wall 126. Theferromagnetic components 110 may be adhesively fixed to a position onthe interior surface 128 using an epoxy, for example.

FIG. 6 illustrates another example configuration of the elastomerichousing 104 in which the ferromagnetic components 110 are positioned onthe exterior surface 130 of the wall 126 of the elastomeric housing 104,according to an example embodiment. In this configuration, theferromagnetic components 110 may be adhesively fixed to a position onthe exterior surface 130 using an epoxy, for example. In addition, inFIG. 6, the ferromagnetic components 110 are embedded in the exteriorsurface 130 so that the ferromagnetic components are flush with theexterior surface 130. This may be useful for installation to avoid markoff or other indentations in a final cured part causes by theferromagnetic components 110.

Thus, as shown in FIGS. 5-6, the ferromagnetic components 110, orpolarized magnetic material, can be positioned on the interior surface128 or the exterior surface 130 of the elastomeric housing 104.

As shown in FIGS. 3-6, the ferromagnetic components 110 are positionedsubstantially homogeneously throughout the elastomeric housing 104.However, in some examples, the ferromagnetic components 110 may bepositioned only along one side of the wall 126, or along a top and abottom of the wall 126, or along sides of the wall 126, or along anycombination of the top, the bottom, and the sides of the wall 126, forexample. For instance, in some examples, the components may be evenlydistributed due to an application requiring full surface rigidity of theelastomeric housing 104, and in other examples, the components may bepositioned at specific locations corresponding to part configurationunder cure and a need for pressure in certain locations during cure.

FIG. 7 illustrates another example configuration of the elastomerichousing 104 in which the ferromagnetic components 110 comprise a coating132 on the interior surface 128 of the wall 126, according to an exampleembodiment. FIG. 8 illustrates another example configuration of theelastomeric housing 104 in which the ferromagnetic components 110comprise the coating 132 on the exterior surface 130 of the wall 126,according to an example embodiment. The coating 132 may include a thinfilm of magnetic material, such as a foil, that can be applied to asurface of the wall. A thickness of the coating 132 may be dependentupon a type of material used, and may in some instances include betweenabout 0.05 inches to about 2 inches, for example. The coating 132 mayprovide sufficient flexibility during the cure process as well.

FIG. 9 illustrates an example configuration of the elastomeric housing104 in which some of the ferromagnetic components 110 a-b are positionedlaterally along the elastomeric housing 104 so as to be linearlyperpendicular to a centerline 134 of the elastomeric housing 104,according to an example embodiment. In addition, other ferromagneticcomponents, such as the ferromagnetic component 110 c, may be positionedat an angle of about 45° with respect to the centerline 134.

FIG. 10 illustrates an example configuration of the elastomeric housing104 in which some of the ferromagnetic components 110 a-b are positionedlongitudinally along the elastomeric housing 104 so as to be linearlyparallel to the centerline 134 of the elastomeric housing, according toan example embodiment. Again in this configuration, the ferromagneticcomponent 110 c may be positioned at an angle of about 45° with respectto the centerline 134.

Thus, as shown in FIGS. 9-10, the ferromagnetic components 110, or thepolarized magnetic material, can be positioned laterally along theelastomeric housing 104 so as to be linearly perpendicular to thecenterline 134 or longitudinally along the elastomeric housing 104 so asto be linearly parallel to the centerline 134. Any combination oflayouts of the ferromagnetic components 110 may also be used so as toprovide the ferromagnetic components 110 positioned laterally,longitudinally, diagonally, or all of these arrangements as well withinthe elastomeric housing 104. Each different configuration may be usedfor optimization of pressure needed based on a configuration of the partundergoing cure.

FIG. 11 illustrates an example configuration of the elastomeric housing104 with the electro-magnetic coil 109 positioned in the elastomerichousing 104, according to an example embodiment. In the example shown inFIG. 11, the electro-magnetic coil 109 is positioned equidistance fromthe top, the bottom, and the sides of the wall 126 of the elastomerichousing 104. In some examples, the electro-magnetic coil 109 can bepositioned equidistance from portions of the interior surface 128 of thewall 126 in instances in which the elastomeric housing 104 may becircular, for example.

FIG. 11 illustrates the elastomeric housing 104 having a rigid exteriorsurface 130. In FIG. 11, the electro-magnetic coil 109 is operated togenerate magnetic fields to repel the ferromagnetic components 110 ofthe elastomeric housing 104 outward as shown by the arrows. In this way,the magnetic field pushes the ferromagnetic components 110 away from theelectro-magnetic coil 109. The electro-magnetic coil 109 is suspendedwithin the elastomeric housing 104 when operated to generate themagnetic fields. When not being operated, the electro-magnetic coil 109may fall to a bottom wall of the elastomeric housing 104 due to gravity.The electro-magnetic coil 109 may alternatively be positioned within acontainer inside the elastomeric housing 104 that holds theelectro-magnetic coil 109 within a center area of the elastomerichousing 104.

FIG. 12 illustrates an example configuration of the elastomeric housing104 with the electro-magnetic coil 109 positioned in the elastomerichousing 104 and operated to collapse the elastomeric housing 104,according to an example embodiment. The electro-magnetic coil 109 isoperated to attract the ferromagnetic components 110 to theelectro-magnetic coil 109 which draws in the interior surface 128 andthe exterior surface 130 of the wall 126. Thus, the elastomeric housing104 collapses inward in this state. The electro-magnetic coil 109 may beactivated to attract all sides of the elastomeric housing 104 evenly dueto a configuration and placement of the ferromagnetic components 110. Inexamples where the electro-magnetic coil 109 is suspended or otherwisemounted within the center area of the elastomeric housing 104,attraction of all sides of the elastomeric housing 104 in an evendistribution may be more beneficial.

In FIG. 11, the ferromagnetic components 110 of the elastomeric housing104 are repelled by the electro-magnetic coil 109 and the elastomerichousing 104 has a first volume as shown. In FIG. 12, the ferromagneticcomponents 110 of the elastomeric housing 104 are attracted to theelectro-magnetic coil 109 and the elastomeric housing 104 has a secondvolume that is smaller than the first volume. In this manner, theelastomeric housing 104 is collapsible.

To operate the electro-magnetic coil 109, a first current may be appliedto the electro-magnetic coil to generate the magnetic fields to attractthe ferromagnetic components 110 of the elastomeric housing 104, and asecond current may be applied to the electro-magnetic coil 109 that isin a direction opposite the first current so as to generate the magneticfields to repel attract the ferromagnetic components 110 of theelastomeric housing 104. Operation of the electro-magnetic coil 109 maybe manual, such as by manually operating the power source 111 forexpansion and retraction of the elastomeric housing 104. In otherexamples, operation of the electro-magnetic coil 109 may be performed ina programmatic manner using a microprocessor programmed to cause thepower source 111 to provide current of a corresponding polarity to theelectro-magnetic coil 109 to attract or repel the ferromagneticcomponents 110 as needed to cause a rigid of flexible exterior surface130. More or less power can be provided to the electro-magnetic coil 109to create stronger or weaker magnetic fields. A strength of the magneticfield may be determined based on an application of use, or based on howmuch ferromagnetic material is included in the elastomeric housing 104,for example.

With the ferromagnetic components 110 evenly distributed through theelastomeric housing 104, a magnetic field generated by theelectro-magnetic coil 109 may be evenly distributed to evenly attract orrepel the wall 126 of the elastomeric housing 104. In one example, theelectro-magnetic coil 109 generates magnetic fields to repel or attractthe ferromagnetic components 110 of the elastomeric housing 104 to theelectro-magnetic coil 109 along a cross-section of the elastomerichousing 104. In other examples, the electro-magnetic coil 109 generatesthe magnetic fields to repel or attract the ferromagnetic components 110of the elastomeric housing 104 to the electro-magnetic coil 109 along alength of the elastomeric housing 104. Still further, theelectro-magnetic coil 109 may generate the magnetic fields to repel orattract the ferromagnetic components 110 of the elastomeric housing 104to the electro-magnetic coil 109 along the cross-section and along thelength of the elastomeric housing 104. Operation of the electro-magneticcoil 109 may be performed to repel or attract the ferromagneticcomponents as needed based on a configuration of the part undergoingcure, for example.

FIG. 13 illustrates an example of the mandrel 100 including a pluralityof tool segments 106 connected to each other within the elastomerichousing 104, according to an example embodiment. In this exampleconfiguration, each tool segment 106 includes an electro-magnetic coil109 and the elastomeric housing 104 includes the ferromagneticcomponents 110. The mandrel 100 also includes a plurality of the jointlinkages 108 coupling or connecting the plurality of tool segments 106in a sequential manner. The power source 111 is positioned outside ofthe elastomeric housing 104 and is connected to each of theelectro-magnetic coils 109 through power cables 173, 174, and 175, forexample. The plurality of joint linkages 108 allow for movement of theplurality of tool segments 106 with respect to each other.

Thus, in the example configuration shown in FIG. 13, each tool segment106 includes an electro-magnetic coil 109 and the power source 111functions to operate all of the tool segments 106 simultaneously. Theinterlocking tool segments 106 are positioned inside the elastomerichousing 104, which may be a flexible elastic bladder, and the jointlinkages 108 allow for flexibility of the mandrel 100 so that themandrel 100 can fit to a contour inside a stringer and also maintainrigidity. In some examples, some of the tool segments 106 may havedifferent cross-sections to allow the mandrel 100 to accommodatevariations in part cross-sections along a length of the part.

The joint linkages 108 provide separation between the tool segments 106,and allow for movement among the tool segments 106. The power cables173, 174, and 175 are positioned through a respective tool segment 106and attach to the respective joint linkage 108.

The joint linkages 108 couple to a substantially center region of thetool segments 106, and multiple connected plates 176 are provided toenclose respective gaps between adjacent tool segments 106. The multipleconnected plates 176 slide over each other to allow for movement of thetool segments 106 with respect to each other.

FIG. 14 illustrates an example of the multiple connected plates 176,according to an example embodiment. The multiple connected platesinclude plates 180, 182, 184, and 186. The plate 180 is connected atpivot point 188 to the plate 182. The plate 182 is connected at pivotpoint 190 to the plate 184. The plate 184 is connected at pivot point192 to the plate 186. The multiple connected plates 176 act like anelbow joint and allow the plates 180, 182, 184, and 186 to slide overeach other to allow for movement while enclosing gaps between the toolsegments 106. The plates 180, 182, 184, and 186 may be metal plates,plastics plates, rubber plates, etc., that allow for movement.

The mandrel 100 shown in FIG. 14 can be configured to have any number oftool segments 106 as needed for a particular use. As one example, for arepair of a composite part, a total length of the mandrel may be betweenabout 6-12 inches long, and each tool segment 106 may be a few inches(e.g., 3-5 inch pieces). The length of the mandrel 100 can be extendedby attaching on another tool segment 106 at an end joint linkage.

In operation, for a repair, the mandrel 100 can be operated to shrink orcollapse to fit into a cavity of the composite part, and then operatedto conform to a contour down a length of the cavity. The collapsiblemandrel 100 is operated by providing a current down electromagneticchain of electro-magnetic coils 109 so that a magnetic field generatedrepels against the interior surface 128 of the elastomeric housing 104causing the mandrel to expand or inflate. The mandrel 100 could beinserted into a contoured area, and then expanded and used as astructural rigid component. When the current is reversed, the magneticfield generated reverses and the wall 126 of the elastomeric housing 104collapses so that the mandrel 100 can be easily removed from the area.Intensity of the magnetic field can be determined by an amount ofcurrent applied. This enables a pressure of the mandrel 100 against thecomposite being cured to be fine-tuned.

FIG. 15 shows a flowchart of an example method 300 for operating themandrel 100, according to an example embodiment. Method 300 shown inFIG. 15 presents an embodiment of a method that, for example, could beused for the mandrel shown in FIG. 1, for example. In some examples,components of the mandrel 100 may be arranged to be adapted to, capableof, or suited for performing the functions, such as when operated in aspecific manner. Method 300 may include one or more operations,functions, or actions as illustrated by one or more of blocks 302-308.Although the blocks are illustrated in a sequential order, these blocksmay also be performed in parallel, and/or in a different order thanthose described herein. Also, the various blocks may be combined intofewer blocks, divided into additional blocks, and/or removed based uponthe desired implementation.

It should be understood that for this and other processes and methodsdisclosed herein, flowcharts show functionality and operation of onepossible implementation of present embodiments. Alternativeimplementations are included within the scope of the example embodimentsof the present disclosure in which functions may be executed out oforder from that shown or discussed, including substantially concurrentor in reverse order, depending on the functionality involved, as wouldbe understood by those reasonably skilled in the art.

At block 302, the method 300 includes providing the elastomeric housing104 having the ferromagnetic components 110. At block 304, the method300 includes operating one or more electro-magnetic coils 109 in theelastomeric housing 104 to generate one or more magnetic fields to repelor attract the ferromagnetic components 110 of the elastomeric housing104 to the one or more electro-magnetic coils 109. At block 306, themethod 300 includes when the ferromagnetic components 110 of theelastomeric housing 104 are repelled by the one or more electro-magneticcoils 109, the elastomeric housing 104 has a rigid surface state. Atblock 308, the method 300 includes when the ferromagnetic components 110of the elastomeric housing 104 are attracted to the one or moreelectro-magnetic coils 109, the elastomeric housing 104 is collapsed.

FIG. 16 shows a flowchart of another example method 320 for operatingthe mandrel 100, according to an example embodiment. At block 322, themethod 320 includes inserting the elastomeric housing 104 into aninternal cavity 204 of a composite part 200 being cured. At block 324,the method 320 includes operating the one or more electro-magnetic coils109 in the elastomeric housing 104 to generate one or more magneticfields to repel the ferromagnetic components 110 of the elastomerichousing 104 by the one or more electro-magnetic coils 109 so as to causethe elastomeric housing 104 to have the rigid surface state. At block326, the method 320 includes subsequently operating the one or moreelectro-magnetic coils 109 in the elastomeric housing 104 to generateone or more magnetic fields to attract the ferromagnetic components 110of the elastomeric housing 104 to the one or more electro-magnetic coils109 so as to cause the elastomeric housing 104 to collapse after cure ofthe composite part 200. At block 328, the method 320 includes removingthe elastomeric housing 104 from the internal cavity 204 of thecomposite part 200.

In some examples, the mandrel 100 may be operated to progress throughmore than one energized cycle during curing, so as to cause theelastomeric housing 104 to have the rigid surface state and collapsedstate multiple times depending on a type of part to be cured such thatthe elastomeric housing 104 may not be removed after one energizedcycle, for example.

Thus, in operation, the mandrel 100 can be operated to have the rigidsurface state for curing, and then collapsed to be removed from thecured part. Magnetic components and the use of a magnetic field replacesuse of pneumatic or other pressure as needed for tooling applications.

Within examples, the mandrel 100 can be used during manufacture ofcomposite parts, or during repair of composite parts. Embodiments of thedisclosure may find use in a variety of potential applications,particularly in the transportation industry, including for example,aerospace, marine, automotive applications and other application whereautoclave curing of composite parts may be used. As one example,embodiments of the disclosure may be used in the context of an aircraftmanufacturing and service. Aircraft applications of the disclosedembodiments may include, for example, without limitation, curing ofstiffener members such as, without limitation beams, spars andstringers, to name only a few.

The description of the different advantageous arrangements has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. Further, different advantageousembodiments may describe different advantages as compared to otheradvantageous embodiments. The embodiment or embodiments selected arechosen and described in order to explain the principles of theembodiments, the practical application, and to enable others of ordinaryskill in the art to understand the disclosure for various embodimentswith various modifications as are suited to the particular usecontemplated.

What is claimed is:
 1. A method comprising: providing an elastomerichousing having ferromagnetic components; operating one or moreelectro-magnetic coils in the elastomeric housing to generate a firstmagnetic field to repel the ferromagnetic components of the elastomerichousing from the one or more electro-magnetic coils and to generate asecond magnetic field to attract the ferromagnetic components of theelastomeric housing to the one or more electro-magnetic coils, whereinwhen the ferromagnetic components of the elastomeric housing arerepelled by the one or more electro-magnetic coils the elastomerichousing has a rigid surface state and when the ferromagnetic componentsof the elastomeric housing are attracted to the one or moreelectro-magnetic coils the elastomeric housing is collapsed; andproviding a plurality of tool segments within the elastomeric housingand coupled in a sequential manner, wherein the one or moreelectro-magnetic coils comprise a plurality of electro-magnetic coilswithin the plurality of tool segments, and wherein the plurality of toolsegments are positioned inside the elastomeric housing; and providingjoint linkages coupling each adjacent tool segment of the plurality oftool segments to each other, wherein the joint linkages enableflexibility of the plurality of tool segments and provide separationbetween each of the plurality of tool segments.
 2. The method of claim1, further comprising: providing a plurality of power cables positionedthrough each of the plurality of tool segments and attached torespective joint linkages.
 3. The method of claim 1, further comprising:inserting the elastomeric housing into an internal cavity of a compositepart being cured; operating the one or more electro-magnetic coils in aprogression through more than one energized cycle during curing of thecomposite part.
 4. The method of claim 1, further comprising: insertingthe elastomeric housing into an internal cavity of a composite part;operating the one or more electro-magnetic coils such that theelastomeric housing has the rigid surface state.
 5. The method of claim1, further comprising: inserting the elastomeric housing into aninternal cavity of a composite part being cured; operating the one ormore electro-magnetic coils such that the elastomeric housing iscollapsed to be removed from the composite part after curing thecomposite part.
 6. The method of claim 1, wherein the one or moreelectro-magnetic coils are operated to generate the first magnetic fieldby receiving a first current, and wherein the one or moreelectro-magnetic coils are operated to generate the second magneticfield by receiving a second current that is a direction opposite thefirst current.
 7. The method of claim 1, further comprising: insertingthe elastomeric housing into an internal cavity of a composite partbeing cured; operating the one or more electro-magnetic coils in theelastomeric housing to generate the first magnetic field to repel theferromagnetic components of the elastomeric housing by the one or moreelectro-magnetic coils so as to cause the elastomeric housing to havethe rigid surface state; subsequently operating the one or moreelectro-magnetic coils in the elastomeric housing to generate the secondmagnetic field to attract the ferromagnetic components of theelastomeric housing to the one or more electro-magnetic coils so as tocause the elastomeric housing to collapse after cure of the compositepart; and removing the elastomeric housing from the internal cavity ofthe composite part.
 8. The method of claim 1, wherein the ferromagneticcomponents are adhesively fixed on an interior surface of at least oneof a plurality of walls of the elastomeric housing using an epoxy. 9.The method of claim 1, wherein when the ferromagnetic components of theelastomeric housing are attracted to the one or more electro-magneticcoils, an interior surface of a wall of the elastomeric housing is drawninward.
 10. The method of claim 1, wherein the ferromagnetic componentsare embedded within at least one of a plurality of walls of theelastomeric housing.
 11. The method of claim 1, wherein theferromagnetic components are positioned on an interior surface of atleast one of a plurality of walls of the elastomeric housing.
 12. Themethod of claim 1, wherein the ferromagnetic components are positionedon an exterior surface of at least one of a plurality of walls of theelastomeric housing.
 13. A mandrel comprising: an elastomeric housinghaving a polarized magnetic material; one or more electro-magnetic coilspositioned within the elastomeric housing and operable to generate afirst magnetic field to repel the polarized magnetic material of theelastomeric housing from the one or more electro-magnetic coils and togenerate a second magnetic field to attract the polarized magneticmaterial of the elastomeric housing to the one or more electro-magneticcoils, wherein when the polarized magnetic material of the elastomerichousing is repelled by the one or more electro-magnetic coils theelastomeric housing has a first volume and when the polarized magneticmaterial of the elastomeric housing is attracted to the one or moreelectro-magnetic coils the elastomeric housing has a second volume thatis smaller than the first volume; a plurality of tool segments withinthe elastomeric housing and coupled in a sequential manner, wherein theone or more electro-magnetic coils comprise a plurality ofelectro-magnetic coils within the plurality of tool segments; and jointlinkages coupling each adjacent tool segment of the plurality of toolsegments to each other, wherein the joint linkages enable flexibility ofthe plurality of tool segments and provide separation between each ofthe plurality of tool segments.
 14. The mandrel of claim 13, wherein thepolarized magnetic material comprises ferromagnetic components, andwherein the elastomeric housing comprises a mixture of ferromagneticcomponents and rubber.
 15. The mandrel of claim 13, wherein thepolarized magnetic material is positioned on an interior wall or anexterior surface of the elastomeric housing.
 16. The mandrel of claim13, wherein the polarized magnetic material is positioned laterallyalong the elastomeric housing so as to be linearly perpendicular to acenterline of the elastomeric housing or longitudinally along theelastomeric housing so as to be linearly parallel to the centerline ofthe elastomeric housing.
 17. The mandrel of claim 13, wherein thepolarized magnetic material is adhesively fixed on an interior surfaceof at least one of a plurality of walls of the elastomeric housing usingan epoxy.
 18. The mandrel of claim 13, further comprising: a pluralityof power cables positioned through each of the plurality of toolsegments and attached to respective joint linkages.
 19. The mandrel ofclaim 13, wherein the one or more electro-magnetic coils are operated togenerate the first magnetic field by receiving a first current, andwherein the one or more electro-magnetic coils are operated to generatethe second magnetic field by receiving a second current that is adirection opposite the first current.
 20. The mandrel of claim 13,wherein when the polarized magnetic material of the elastomeric housingis attracted to the one or more electro-magnetic coils, an interiorsurface of a wall of the elastomeric housing is drawn inward.